Removable door surround for a folding soft top

ABSTRACT

A door rail surround assembly incorporating an anti-rotation feature added to a door rail clamp of the assembly. The anti-rotation feature is a net fit cross vehicle with a hole in the vehicle sport bar thereby eliminating any free movement of the door rail clamp assembly. A second clamp is rotatable for also receiving a fastener of the door rail clamp. A clamp load is applied to the vehicle when the fastener is inserted and torqued to its predetermined value. This clamping load prevents any free movement in the door rail clamp assembly when the door seal load is applied when the vehicle door is closed.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/958,025, filed Apr. 20, 2018, which claims the benefit of U.S.Provisional Application No. 62/487,763, filed Apr. 20, 2017. Thedisclosures of the above applications are incorporated herein byreference.

FIELD OF THE INVENTION

The present invention relates to a door rail assembly with anti-rotationfeatures.

BACKGROUND OF THE INVENTION

Foldable roof soft tops are commonly used in sport-utility vehicles formoving between a closed position, and a sunroof position or further toone or more stowed positions. When in the closed position, the foldableroof protects the occupants of the vehicle from various weatherconditions. However, there are occasions when it is desired by theoccupants of the vehicle to move the foldable roof to an open positionsuch that the vehicle essentially functions without part of a roof oressentially functions without a roof, or remove the top from thevehicle, and at least the passenger compartment of the vehicle isexposed to the atmosphere. This allows the occupants of the vehicle toenjoy more favorable weather conditions while driving.

The foldable soft tops are mounting to the vehicle. Known systems aredescribed in U.S. Pat. Nos. 5,947,546 and 6,036,256. In conventionalsystems, U.S. Pat. No. 6,036,256, for example, the door seal applies aload to the door rail surround in the cross car direction when thevehicle door is closed. Due to build variations and component buildtolerances in the vehicle body sport bar and the door rail surround,this load applies a force vector on the surround that results in thesurround rotating about the vehicle body sport bar. This rotation of thedoor rail surround causes a poor fitting surround and reduces thesealing efficiency of the door sealing system resulting in potentialwater leak conditions into the vehicle interior.

Accordingly, there exists a need for an improved door rail surround withbuilt in anti-rotation when fastened to the vehicle to eliminate freemovement of the door rail when the door seal load is applied when thevehicle door is closed.

SUMMARY OF THE INVENTION

The present invention is directed to a door rail surround assemblyincorporating an anti-rotation feature added to a door rail clamp. Whenfastened to the vehicle, the anti-rotation feature is a net fit crossvehicle with the vehicle attachment location thereby eliminating anyfree movement of the door rail clamp assembly. A second clamp isrotatable for also receiving a fastener of the door rail clamp. A clampload is applied to the vehicle when the fastener is inserted and torquedto its predetermined value. This clamping load prevents any freemovement in the door rail clamp assembly when the door seal load isapplied when the vehicle door is closed.

Further areas of applicability of the present invention will becomeapparent from the detailed description provided hereinafter. It shouldbe understood that the detailed description and specific examples, whileindicating the preferred embodiment of the invention, are intended forpurposes of illustration only and are not intended to limit the scope ofthe invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from thedetailed description and the accompanying drawings, wherein:

FIG. 1 is a sectional view of a conventional rail surround connected toa vehicle body sport bar, illustrating a door seal pressed against thedoor rail surround when a vehicle door assembly is closed;

FIG. 2 is the sectional view of FIG. 1 depicting the direction of thedoor seal applying a load to the door rail surround, and an arrowillustrating the direction of rotation of the door rail surround aboutthe vehicle sport bar from the applied load;

FIG. 3 is a rear perspective view of a vehicle with an exemplary softtop assembly and a door rail surround assembly, in accordance with thepresent invention;

FIG. 4 is a cross sectional view of the door rail surround assemblyconnected to the vehicle, in accordance with the present invention;

FIG. 5 is the cross section view of FIG. 4 depicting door seal loadingand clamping load directions indicated by arrows, in accordance with thepresent invention;

FIGS. 6A-6D are perspective views depicting installation of the doorrail surround assembly to the vehicle, in accordance with the presentinvention;

FIGS. 7-10 are cross sectional views depicting installation of the doorrail surround assembly to the sport bar of the vehicle, in accordancewith the present invention;

FIG. 11 is a perspective view illustrating the door rail surroundassembly connected to the vehicle sport bar, in accordance with thepresent invention; and,

FIG. 12 is an exploded view of the clamp assembly of the door railsurround assembly, in accordance with the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following description of the preferred embodiment(s) is merelyexemplary in nature and is in no way intended to limit the invention,its application, or uses.

Referring to FIGS. 1-2, there is depicted a known door rail surround 10connected to a vehicle body sport bar 12. The rail surround 10 is insealing engagement with a door seal 14 of a door assembly 16. The railsurround 10 includes a top cover retainer 18 connected to a top cover20, and a door rail fastener 22 to connect the door rail surround 10 tothe vehicle sport bar 12. The door seal 14 of the door assembly 16applies a load (indicated by arrow ‘A’) to the door rail surround 10 inthe cross car direction when the vehicle door is closed, e.g., in adirection toward the vehicle interior. Due to build variations andcomponent build tolerances in the vehicle body sport bar 12 and the doorrail surround 10, this load ‘A’ applies a force vector on the surround10 that results in the surround 10 rotating (indicated by arrow ‘B’)about the vehicle body sport bar 12. This rotation of the door railsurround 10 causes a poor fitting surround 10 and reduces the sealingefficiency of the door sealing system resulting in potential water leakconditions into the vehicle interior.

Referring to FIGS. 3-12 generally, a door surround assembly according tothe present invention is shown generally at 100 for a soft top assembly.An exemplary soft top assembly is shown generally at 102. At least onedoor surround assembly is mountable to the vehicle 104 and is operablyselectively removable. Preferably, at least one pair of door surroundassemblies 104 are mounted at each side of the vehicle adjacent a rooftop opening. At least one door seal of the door assembly can be providedand pressed against the door surround assembly 100 to provide a weathertight seal when the vehicle door is closed. The door rail surroundassembly 100 is mounted to the vehicle and stays in place whether or notthe soft top is closed/opened or removed. However, the door surround 100is designed to be removable, for efficient removal when desired.

The door rail surround assembly (or “assembly”) 100 includes at leastone door rail surround portion shown generally at 106 and at least onedoor rail clamp assembly portion shown generally at 108 including atleast two halves. Each door rail clamp assembly portion 108 has at leastone first clamp half 110, e.g., upper clamp 110, and at least one secondclamp half 112, e.g., lower clamp. The first and second clamps 110,112operably connect to a vehicle structure, most preferably a sport bar 114by at least one fastener 116. The first clamp 110 is most preferablyoperably fixedly connected to the door rail surround portion 106.Preferably, the first clamp 110 includes a protruding portion 111 thatreceives the fastener 116, most preferably, a threaded end 117 of thefastener 116. The second clamp 112 includes at least one aperture 115that receives the at least on fastener 116.

The second clamp 112 is operably pivotally connected to the door railsurround portion 106, preferably, pivotally connected to the first clamp110, and rotates to a clamping position (as indicated by arrow ‘F’ inFIG. 9). Most preferably, the second clamp 112 is pivotally connected tothe first clamp 110 by at least one pivot joint 113.

At least one anti-rotation feature 118 is provided on the door railclamp assembly portion 108 to prevent the clamp assembly portion 108from rotating. Typically, the at least one anti-rotation feature 118 isintegrally formed with the first clamp 110. Preferably, the at least oneanti-rotation feature 118 extends from a surface of the first clamp 110in a direction generally toward the top of the sport bar 114. Mostpreferably, the at least one anti-rotation feature 118 is a boss. Theanti-rotation feature 118 is inserted into a fastener aperture 120located in the vehicle body, e.g., preferably, a fastener aperture 120of the sport bar 114, most preferably, an aperture 120 on the uppersurface of the sport bar 114. The anti-rotation feature 118 is a net fitcross vehicle inside the aperture 120 thereby eliminating any freemovement of the door rail clamp assembly 108. A clamp load (indicatedgenerally by arrows ‘C’ in FIG. 5) is applied to the vehicle body sportbar 114 when the fastener 116 is inserted (into the clamp assembly 108and sport bar 114) and torque applied (e.g., as indicated by arrow ‘E’in FIG. 10) to a predetermined value. This clamping load prevents anyfree movement in the door rail clamp assembly 108 (and surround 106)when the door seal load (as indicated by arrow ‘D’ in FIG. 5) is appliedwhen the vehicle door is closed in the direction indicated by arrow ‘D’.

At least one second aperture 121 is located in the vehicle structure114, preferably, on a bottom surface of the sport bar 114 to receive theat least one fastener 116 into the aperture 115 of the second clamp 112and into the sport bar 114.

While a threaded fastener 116 is depicted, it is understood that the atleast one fastener 116 may be any other fastener and arrangementsuitable to securely connect the clamp assembly 108 to a predeterminedvehicle structure, depending on the particular application withoutdeparture from the scope of the present invention.

The soft top assembly 102 includes at least one top cover 122 thatcovers the roof top opening. Preferably, the top cover 122 includes abinding 123 on a side top deck portion, and, when in the top closedposition, comes over the top of the door rail surround 106 and operablyengages at least one sealing feature 125 of the door rail surround 106,most preferably, resting against the outward facing surface of thesealing feature 125. When closed, the top cover 122 and door railsurround portion 106 operably create a weather resistant seal.Preferably, the door seal 14 engages against the outward facing surface127 of a protruding feature on the door rail surround 106 when thevehicle door 16 is closed.

Preferably, there are at least two clamping assemblies 108 located oneach door surround assembly 100. Most preferably, each door surround 106has at least two clamping assemblies 108 that each align with at leastone predrilled original equipment manufacturer aperture in the sport bar114 for each of the at least one fastener 116 so that a no-drillinstallation of the door surround assembly 100 is possible.

Referring more particularly to FIGS. 11 and 12, the clamp assembly 108includes a clamp pivot pin 124 and biasing member 126, e.g., torsionspring, operable for a pivotal connect of the second clamp 112 to thefirst clamp 110. The first clamp 110 includes at least one hinge portion128, preferably, a pair of hinge portions 128, each including anaperture 128 a. The second clamp 112 includes at least one aperture 130,preferably, a pair of apertures 130. Most preferably, the pin 124extends through the plurality of apertures 128 a,130.

The clamp assembly 108 is operably connected to the door surround 106.Preferably, the first clamp 110 is connected to the door surround 106with adhesive and/or at least one fastener, most preferably, at leasttwo fasteners (such as screws). Most preferably, at least one threadedinsert 132, preferably, at least one pair of threaded inserts 132, areinserted into at least one aperture 134, preferably, a pair of apertures134, formed in the first clamp 110. These threaded inserts 132 allow thefastener to grip for attachment of the first clamp 110 to the doorsurround 106.

Another threaded insert 136 is located in another aperture 138 in thefirst clamp 110 to engage the fastener 116. Preferably, the threadedinsert is in the protruding portion 111 of the first clamp 110.

Referring now more particularly to FIGS. 6A-10, the door surroundassembly 100 is connected to the sport by 114 by aligning the door railassembly 100 with predetermined areas of the vehicle body sport bar 114(e.g, see FIGS. 6A and 7). The door rail assembly's anti-rotationfeature 118 is inserted into the aperture 120 of the vehicle body sportbar 114 (e.g., see FIG. 8). The second clamp 112 is rotated to alignwith the other aperture 121 in the sport bar 114 (e.g., see FIGS. 6D and9). Preferably, the apertures 120,121 are on opposing sides of the sportbar 114 such as the top and bottom surfaces. The first and second clamps110,112 are then secured to the sport bar 114 with the fastener 116 (seeFIG. 10), which secures the door rail to the vehicle. Preferably, eachdoor surround assembly 100 has two clamp assemblies 108. It isunderstood that more or less than two clamp assemblies 108 for each doorrail surround 106 are contemplated without departure from the scope ofthe present invention.

The door surround assembly 100 can be a single segment or more than onesegment. Preferably, the door surround 106 expanse is generally over thefront door. Alternatively, adapted for at least generally over the reardoor. Alternatively, adapted for generally over the front and rear doorin a single or multiple piece segment. In a most preferred embodiment,the door surround is over the front door, and a coupled rear doorsegment includes a track or channel for receiving slidable features ofthe soft top assembly to slide for stowing rear of the rear cockpit orremoving the top from the vehicle. Most preferably, for four-doorvehicles, for example, the door rail surround 106 is a front doorsurround and is operably coupled to a rear door surround 106 a orintegrally formed therewith. It is understood that the door railsurround 106 can be a single piece or multiple pieces operably connectedtogether, e.g., adhesive and/or at least one fastener, depending on theapplication without departure from the scope of the present invention.

With the arrangement and combination of features of the presentinvention, the door rail surround assembly 100 is selectively removablefrom the vehicle, when desired, and easily reinstalled, as desired.

The left side door surround assembly is a substantially mirror image tothe right side 100 depicted in the figures.

While a 4-door vehicle is illustrated, it is understood that the presentinvention is adaptable for a 2-door vehicle, 2 or 4-door SUV withextended cargo area, slanted back, folding/sliding soft top, frontcompartment soft top, front and rear compartment soft top, full roofsoft top, soft top with linkages for rotation to sunroof positions, softtop incorporating fabric management bows, lift assist soft tops, anyother suitable top, hard top, etc, and combinations thereof withoutdeparture from the scope of the present invention.

The description of the invention is merely exemplary in nature and,thus, variations that do not depart from the essence of the inventionare intended to be within the scope of the invention. Such variationsare not to be regarded as a departure from the spirit and scope of theinvention.

What is claimed is:
 1. A door rail surround assembly adapted for a softtop assembly for a convertible roof of a vehicle, comprising: a doorrail surround portion; at least one door rail clamp assembly operablyconnected to the door rail surround portion and adapted to connect to apredetermined vehicle structure with at least one fastener that hasthreads, said door rail clamp assembly including an anti-rotationfeature that restricts free movement of the door rail surround assembly;wherein the door rail clamp assembly includes at least a first clamp anda second clamp, wherein said second clamp is rotatable.
 2. The door railsurround assembly of claim 1, wherein said first or second clamp isconnected to said door rail surround portion.
 3. The door rail surroundassembly of claim 2, further comprising at least one threaded insertlocated in a respective aperture formed in the first clamp for operablyfastening said first clamp to said door rail surround portion.
 4. Thedoor rail surround assembly of claim 1, wherein said second clamp isrotatably connected to said first clamp.
 5. The door rail surroundassembly of claim 4, wherein the door rail clamp assembly includes a pinextending through a plurality of apertures on the first and secondclamps for a pivotal connection.
 6. The door rail surround assembly ofclaim 4, wherein said second clamp includes an aperture to receive saidat least one fastener.
 7. The door rail surround assembly of claim 1,further comprising at least one threaded insert located in a respectiveaperture formed in said at least one door rail clamp assembly to connectsaid at least one fastener to said at least one door rail clampassembly.
 8. The door rail surround assembly of claim 1, wherein thedoor rail surround portion includes at least one sealing feature with asurface adapted for sealing engagement with a door seal.
 9. The doorrail surround assembly of claim 1, wherein each door rail clamp assemblyfurther includes: said first clamp having an aperture for said fastener;and said second clamp having another aperture for said fastener, whereinsaid vehicle structure is a sport bar including an upper aperture and alower aperture, and wherein said at least one fastener extends into saidfirst and second clamp apertures and said sport bar apertures to securesaid door rail clamp assembly to said sport bar.
 10. The door railsurround assembly of claim 9, wherein said first clamp is positioned ontop of said sport bar of said vehicle and said second clamp is rotatableto the bottom of said sport bar and then said at least one fastener isinserted to secure the door rail clamp assembly to said sport bar. 11.The door rail surround assembly of claim 1, wherein said anti-rotationfeature is a boss that is inserted into an aperture formed in saidvehicle structure.
 12. The door rail surround assembly of claim 11,wherein said boss is provided on said first clamp that is an upper clampof said door rail clamp assembly and is inserted into said aperture ofsaid vehicle structure to connect to said second clamp that is a lowerclamp by said at least one fastener received in said lower clamp andsaid boss.
 13. The door rail surround assembly of claim 12, wherein aclamp load is applied to said sport bar when said at least one fasteneris inserted into said boss and torqued to a predetermined value.
 14. Thedoor rail surround assembly of claim 1, wherein at least two door railclamp assemblies are connected to each door rail surround.
 15. Aremovable door rail surround assembly adapted for a soft top assemblyfor a convertible roof of a vehicle, comprising: a door rail surroundportion with a surface adapted for a door seal to press against in aload direction; a pair of door rail clamp assemblies connected to thedoor rail surround portion, each of said door rail clamp assembliesincluding a first clamp operably connected to said door rail surroundportion and a second clamp rotatably connected to said first clamp; ananti-rotation feature provided on each of said first clamps, said eachanti-rotation feature adapted to insert into a respective apertureformed in a sport bar of said vehicle to restrict free movement of saiddoor rail clamp assembly; and a threaded portion provided in an apertureof said first clamp for connecting to at least one fastener that hasthreads, wherein said at least one fastener is adapted to secure thefirst and second clamps to opposing upper and lower surfaces of saidsport bar.
 16. The removable door rail surround assembly of claim 15,wherein said second clamp is hinged to said first clamp by a pin andbiasing member.
 17. The removable door rail surround assembly of claim15, wherein, with said anti-rotation feature inserted into said sportbar aperture, said fastener extends through aligned apertures formed inthe second clamp, bottom and top surfaces of said sport bar, and intosaid anti-rotation feature where said fastener is secured by threadslocated in the anti-rotation feature, wherein a clamp load restrictsfree movement of said door rail clamp assembly when a door seal load isapplied when a vehicle door is closed.